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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G3500, VAN PASSENGER EXTENDEDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 808 (ENGINE EXHAUST SYSTEM)REPAIR INSTRUCTIONSEXHAUST MUFFLER REPLACEMENT (L96)INSTALLATION PROCEDURE
2008 Chevrolet Chevy Express G3500, Van Passenger Extended

Installation Procedure

2008 Chevrolet Chevy Express G3500, Van Passenger ExtendedSECTION Installation Procedure
WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2011 GMC Yukon XL, 2011 GMC Yukon, 2011 Chevrolet Tahoe, 2011 Chevrolet Suburban, and 2011 Chevrolet Avalanche. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Exhaust System Hangers And Insulators
    GM1708986Courtesy of GENERAL MOTORS CORP.
  1. If the vehicle is a Yukon XL, Yukon Denali XL, Escalade ESV, or Escalade EXT perform the following steps, otherwise proceed to step 6.
  2. Lubricate the insulators where the muffler assembly hangers are inserted for ease of installation.
    3. NOTE:

    During installation, do not over extend the flex coupler as internal damage may occur.

  3. With the aid of an assistant, install the muffler assembly.
  4. With the aid of an assistant, install the insulators to the exhaust system hangers (3, 4, and 5).
    5. Fig 2: Exhaust System Hangers And Insulator
    GM1708987Courtesy of GENERAL MOTORS CORP.
  5. With the aid of an assistant, Install the insulator to the exhaust system hanger near the resonator.
    6. Fig 3: Exhaust System Hangers & Insulators
    GM1708981Courtesy of GENERAL MOTORS CORP.
  6. If the vehicle is a Yukon Denali or Escalade perform the following:
    • Lubricate the insulators where the muffler assembly hangers are inserted for ease of installation.
    • With the aid of an assistant, install the muffler assembly.
    • With the aid of an assistant, install the insulators to the exhaust system hangers (2, and 3).
    7. Fig 4: View Of Exhaust System Hangers And Insulator
    GM1708983Courtesy of GENERAL MOTORS CORP.
  7. Install the insulator to the exhaust system hanger near the resonator.
    8. Fig 5: Catalytic Converter To Muffler Clamp
    GM2513101Courtesy of GENERAL MOTORS CORP.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.